3A1080G, ProControl 1KS Auto, Operation Manual, English · Intrinsically safe equipment that is installed improper ly or connected to non-int rinsically safe equipment will create

II 2 G0359

3A1080GEN

Operation

ProControl™ 1KSAutomatic system for fluid management of single component coatings. Includes flow control, flushing, and color change. For professional use only.

Approved for use in explosive atmospheres (except the EasyKey).

TI16328a

See pages 4-5 for model information, including maxi-mum working pressure. Equipment approval labels are on page 3. Some components shown are not included with all systems.

Important Safety InstructionsRead all warnings and instructions in this manual. Save these instructions.

2 3A1080G

ContentsRelated Manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3Equipment Approvals . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3System Configuration and Part Numbers . . . . . . . . . . . . 4

Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4Standard Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6Important Two-Component Material Information . . . . . . 8

Isocyanate Conditions . . . . . . . . . . . . . . . . . . . . . . . . . 8Material Self-ignition . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Keep Components A and B Separate . . . . . . . . . . . . . . 8Moisture Sensitivity of Isocyanates . . . . . . . . . . . . . . . . 8Changing Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Glossary of Terms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12Component Identification and Definition . . . . . . . . . . . 12Wall Mount System Components . . . . . . . . . . . . . . . . 14

EasyKey Display and Keypad . . . . . . . . . . . . . . . . . . . . . 16Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16Keypad . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16AC Power Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18I/S Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18Audible Alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18Graco Web Interface Port . . . . . . . . . . . . . . . . . . . . . . 18Ethernet Connection . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Run Mode Screens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19Splash Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19Status Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21Manual Override Screen . . . . . . . . . . . . . . . . . . . . . . . 22Totals Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23Reset Total Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . 23Reset Solvent Screen . . . . . . . . . . . . . . . . . . . . . . . . . 23Alarms Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24Level Control Screen . . . . . . . . . . . . . . . . . . . . . . . . . 24

Setup Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25Password Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26Set Up Home Screen . . . . . . . . . . . . . . . . . . . . . . . . . 26System Configuration Screens . . . . . . . . . . . . . . . . . . 28Option Screens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32Advanced Setup Screens . . . . . . . . . . . . . . . . . . . . . . 34Recipe Setup Screens . . . . . . . . . . . . . . . . . . . . . . . . 40Recipe 0 Screens . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45Calibration Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

ProControl Integration Specifics . . . . . . . . . . . . . . . . . . 49System Setup for Automatic Operation . . . . . . . . . . . . 49Status Verification of Automatic Operation . . . . . . . . . 50Discrete I/O vs Network Communications . . . . . . . . . 50Discrete I/O . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51Automation Flow Charts . . . . . . . . . . . . . . . . . . . . . . . 55

Modbus and I/O Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66Start Mix Process . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66Stop Mix Process . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66Color Change Process . . . . . . . . . . . . . . . . . . . . . . . . 66Purge Process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67Typical PLC Interaction with ProControl 1KS . . . . . . . 69

Integrated Flow Control . . . . . . . . . . . . . . . . . . . . . . . . . 78Flow Control Description . . . . . . . . . . . . . . . . . . . . . . 78Flow Control Components . . . . . . . . . . . . . . . . . . . . . 78Fluid and Air Pressure Requirements . . . . . . . . . . . . . 79Flow Control Operation . . . . . . . . . . . . . . . . . . . . . . . . 79Flow Control Operating Process Example . . . . . . . . . 81Flow Control Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . 83Flow Control Startup . . . . . . . . . . . . . . . . . . . . . . . . . . 83One-Point Learning . . . . . . . . . . . . . . . . . . . . . . . . . . 84Flow Control Calibration . . . . . . . . . . . . . . . . . . . . . . . 85Pressure Flow Control Mode . . . . . . . . . . . . . . . . . . . 88Flow Control Troubleshooting . . . . . . . . . . . . . . . . . . . 89

System Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91Operation Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91Recipe (Color) Change . . . . . . . . . . . . . . . . . . . . . . . . 91Solvent Push . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91Mix Manifold Valve Settings . . . . . . . . . . . . . . . . . . . . 91Start Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94Pressure Relief Procedure . . . . . . . . . . . . . . . . . . . . . 94Purging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98Solvent Push Feature . . . . . . . . . . . . . . . . . . . . . . . . 101

Meter Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102Color Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104

Color Change Procedures . . . . . . . . . . . . . . . . . . . . 104Color Change Sequences . . . . . . . . . . . . . . . . . . . . 104

Alarms and Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . 118System Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118System Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . 118

Alarm Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . 119Schematic Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . 130

System Pneumatic Schematic . . . . . . . . . . . . . . . . . 130System Electrical Schematic . . . . . . . . . . . . . . . . . . 131EasyKey Electrical Schematic . . . . . . . . . . . . . . . . . 133

Meter Performance Data (G3000 on A and B) . . . . . . . 134Meter Performance Data (G3000 on A, Coriolis on B) 135Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137Graco Standard Warranty . . . . . . . . . . . . . . . . . . . . . . . 138Graco Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138

Related Manuals

3A1080G 3

Related ManualsComponent Manuals in English

Equipment ApprovalsEquipment approvals appear on the following labels which are attached to the Fluid Station Control Box and EasyKey™. See FIG. 1 on page 4 for label locations.Manual Description

3A1163 ProControl 1KS Installation3A1164 ProControl 1KS Repair-Parts312782 Dispense Valve312783 Color Change Valve Stacks312787 Color Change Module Kit312784 Gun Flush Box Kits310745 Gun Air Shutoff Kit312786 Dump Valve and Third Purge Valve Kits312785 Network Communication Kits308778 G3000/G3000HR/G250/G250HR Flow

Meter313599 Coriolis Flow Meter313212 Gun Flush Box Integration Kit313290 Floor Stand Kit313542 Beacon Kit313386 Basic Web Interface/Advanced Web

Interface406800 15V825 Discrete I/O Board Kit

.7 7 100MAX AIR WPR

MPa bar PSI

1.31 13.1 190MAX FLUID WPR

MPa bar PSI

PART NO. SERIES

Read Instruction ManualWarning: Substitution of componentsmay impair intrinsic safety.

SERIAL

ProControl 1KSElectronic Proportioner

MAX TEMP 50°C (122°F)

Intrinsically Safe (IS) System. Install per IS Control Drawing No. 289833.EasyKey Interface IS AssociatedApparatus for use in non hazardouslocation, with IS Connection to Smart Fluid Plate ISApparatus for use in:Class I, Division 1, Group D T3 CHazardous Locations

Intrinsically safeequipment for Class I,

Div 1, Group D, T3

Ta = -20°C to 50°C

C USFM08ATEX0074II 2 GEx ia IIA T3

GRACO INC.P.O. Box 1441Minneapolis, MN 55440 U.S.A.

MFG. YR.

SERIES NO. MFG. YR.PART NO.

AMPS

VOLTS 85-250 ~ 2 AMPS MAX

POWER REQUIREMENTS


II (2) G[Ex ia] IIAFM08ATEX0072

Intrinsically safe connectionsfor Class I, Div 1, Group DTa = -20°C to 50°CInstall per 289833

C US

27786950/60 Hz

ProControl 1KS

Um: 250 V

ATEX Certificate is listed here



293765b

293762b

EasyKey Label

Fluid Station Label

EasyKey and Fluid Station Control Box Label

.7 7 100MAX AIR WPR

MPa bar PSI

FLUID PANELProControlPART NO. SERIES SERIAL


Intrinsically safe equipmentfor Class I, Div 1, Group D, T3Ta = -20°C to 50°CInstall per 289833 FM08ATEX0073

II 2 GEx ia IIA T3

System Configuration and Part Numbers

4 3A1080G


ModelsThe part number for your equipment is printed on the equipment identification labels. See FIG. 1 for location of the identification labels.

Part No. Series Description

Meter Flow Control

None G3000 Coriolis No Yes

262380 A ProControl 1KS




FIG. 1: Identification Label, ProControl 1KS Systems

.7 7 100MAX AIR WPR

MPa bar PSI

1.31 13.1 190MAX FLUID WPR

MPa bar PSI

PART NO. SERIES

Read Instruction ManualWarning: Substitution of componentsmay impair intrinsic safety.

SERIAL

ProControl 1KSElectronic Proportioner

MAX TEMP 50°C (122°F)

Intrinsically Safe (IS) System. Install per IS Control Drawing No. 289833.EasyKey Interface IS AssociatedApparatus for use in non hazardouslocation, with IS Connection to Smart Fluid Plate ISApparatus for use in:Class I, Division 1, Group D T3 CHazardous Locations

Intrinsically safeequipment for Class I,

Div 1, Group D, T3

Ta = -20°C to 50°C

C USFM08ATEX0074II 2 GEx ia IIA T3


MFG. YR.

Label Location on EasyKey

Label Location on Fluid Station

Maximum FluidWorking Pressure

is listed here

TI15975aTI15974a

Configured Part Number


3A1080G 5

Standard Features Accessories

NOTE: This is not a complete list of available accesso-ries and kits. Refer to the Graco website for more infor-mation about accessories available for use with this product.

Hazardous Location ApprovalModels using a G3000, G3000HR, or intrinsically safe Coriolis meter are approved for installation in a Hazardous Location - Class I, Div I, Group D, T3 or Zone I Group IIA T3.

Maximum Working Pressure

Maximum working pressure rating is dependent on the fluid component options selected. The pressure rating is based on the rating of the lowest rated fluid component. Refer to the component pressure ratings below. Example: Model 262383 has a maximum working pressure of 190 psi (1.31 MPa, 13.1 bar).

Check the identification label on the EasyKey or fluid station for the system maximum working pressure. See FIG. 1.

ProControl Fluid Components Maximum Working PressureBase System (no meter, no color/catalyst change option, and no flow control [option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4000 psi (27.58 MPa, 275.8 bar)G3000 Meter Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4000 psi (27.58 MPa, 275.8 bar)Coriolis Meter Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2300 psi (15.86 MPa, 158.6 bar)Color Change Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 300 psi (2.07 MPa, 20.6 bar)Flow Control Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .190 psi (1.31 MPa 13.1 bar)

Flow Meter Fluid Flow Rate RangeG3000. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75-3800 cc/min. (0.02-1.0 gal./min.)G3000HR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38-1900 cc/min. (0.01-0.50 gal./min.)Coriolis Meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-3800 cc/min. (0.005-1.00 gal./min.)S3000 Solvent Meter (accessory) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38-1900 cc/min. (0.01-0.50 gal./min.)

Feature

EasyKey with LCD

RS 485 Network Cable, 50 ft (15.25 m)

Fiber Optic and Power Cables, 50 ft (15.25 m)

Fluid Station Control Box

Discrete I/O Board

A Side Dump Valve, if color valve(s) selected

Flow Control with 15 ft (4.57 m) Cable (if selected)

Basic Web Interface

Accessory

15V536 Solvent Flow Switch Kit

15V213 Power Cable, 100 ft (30.5 m)

15G710 Fiber Optic Cable, 100 ft (30.5 m)

15G614 Flow Control Extension Cable, 40 ft (12.2 m)

15W034 Strobe Light Alarm Indicator Kit

15V331 Gateway Ethernet Communication Kit

15V963 Gateway DeviceNet Communication Kit

15V964 Gateway Profibus Communication Kit

15V337 Advanced Web Interface

Warnings

6 3A1080G

WarningsThe following warnings are for the setup, use, grounding, maintenance, and repair of this equipment. The exclama-tion point symbol alerts you to a general warning and the hazard symbols refer to procedure-specific risks. When these symbols appear in the body of this manual, refer back to these Warnings. Product-specific hazard symbols and warnings not covered in this section may appear throughout the body of this manual where applicable.

WARNINGFIRE AND EXPLOSION HAZARD Flammable fumes, such as solvent and paint fumes, in work area can ignite or explode. To help prevent fire and explosion:• Use equipment only in well ventilated area.• Eliminate all ignition sources; such as pilot lights, cigarettes, portable electric lamps, and plastic drop

cloths (potential static arc). • Keep work area free of debris, including solvent, rags and gasoline.• Do not plug or unplug power cords, or turn power or light switches on or off when flammable fumes

are present.• Ground all equipment in the work area. See Grounding instructions in your system installation man-

ual.• Use only grounded hoses.• Hold gun firmly to side of grounded pail when triggering into pail.• If there is static sparking or you feel a shock, stop operation immediately. Do not use equipment

until you identify and correct the problem.• Keep a working fire extinguisher in the work area.

ELECTRIC SHOCK HAZARD This equipment must be grounded. Improper grounding, setup, or usage of the system can cause electric shock.• Turn off and disconnect power at main switch before disconnecting any cables and before servicing

equipment.• Connect only to grounded power source.• All electrical wiring must be done by a qualified electrician and comply with all local codes and

regulations.

INTRINSIC SAFETYIntrinsically safe equipment that is installed improperly or connected to non-intrinsically safe equipment will create a hazardous condition and can cause fire, explosion, or electric shock. Follow local regulations and the following safety requirements.

• Only models with a G3000, G250, G3000HR, G250HR, or intrinsically safe Coriolis meter are approved for installation in a Hazardous Location - Class I, Div I, Group D, T3 or Zone I Group IIA T3.

• Do not install equipment approved only for a non-hazardous location in a hazardous area. See the ID label for the intrinsic safety rating of your model.

• Do not substitute or modify system components as this may impair intrinsic safety.

Warnings

3A1080G 7

SKIN INJECTION HAZARD High-pressure fluid from gun, hose leaks, or ruptured components will pierce skin. This may look like just a cut, but it is a serious injury that can result in amputation. Get immediate surgical treatment.• Tighten all fluid connections before operating the equipment.• Do not point gun at anyone or at any part of the body.• Do not put your hand over the spray tip.• Do not stop or deflect leaks with your hand, body, glove, or rag.• Follow Pressure Relief Procedure in this manual, when you stop spraying and before cleaning,

checking, or servicing equipment.

EQUIPMENT MISUSE HAZARD Misuse can cause death or serious injury.• Do not operate the unit when fatigued or under the influence of drugs or alcohol.• Do not exceed the maximum working pressure or temperature rating of the lowest rated system

component. See Technical Data in all equipment manuals.• Use fluids and solvents that are compatible with equipment wetted parts. See Technical Data in all

equipment manuals. Read fluid and solvent manufacturer’s warnings. For complete information about your material, request MSDS forms from distributor or retailer.

• Check equipment daily. Repair or replace worn or damaged parts immediately with genuine manu-facturer’s replacement parts only.

• Do not alter or modify equipment.• Use equipment only for its intended purpose. Call your distributor for information.• Route hoses and cables away from traffic areas, sharp edges, moving parts, and hot surfaces.• Do not kink or over bend hoses or use hoses to pull equipment.• Keep children and animals away from work area.• Comply with all applicable safety regulations.

TOXIC FLUID OR FUMES HAZARD Toxic fluids or fumes can cause serious injury or death if splashed in the eyes or on skin, inhaled, or swallowed.• Read MSDS’s to know the specific hazards of the fluids you are using.• Store hazardous fluid in approved containers, and dispose of it according to applicable guidelines.• Always wear chemically impermeable gloves when spraying or cleaning equipment.

PERSONAL PROTECTIVE EQUIPMENT You must wear appropriate protective equipment when operating, servicing, or when in the operating area of the equipment to help protect you from serious injury, including eye injury, inhalation of toxic fumes, burns, and hearing loss. This equipment includes but is not limited to:• Protective eyewear • Clothing and respirator as recommended by the fluid and solvent manufacturer• Gloves• Hearing protection

WARNING

Important Two-Component Material Information

8 3A1080G

Important Two-Component Material Information

Isocyanate Conditions

Material Self-ignition

Keep Components A and B Separate

Moisture Sensitivity of IsocyanatesIsocyanates (ISO) are catalysts used in two component coatings. ISO will react with moisture (such as humidity) to form small, hard, abrasive crystals, which become suspended in the fluid. Eventually a film will form on the surface and the ISO will begin to gel, increasing in vis-cosity. If used, this partially cured ISO will reduce perfor-mance and the life of all wetted parts.

NOTE: The amount of film formation and rate of crystal-lization varies depending on the blend of ISO, the humidity, and the temperature.

To prevent exposing ISO to moisture:

• Always use a sealed container with a desiccant dryer in the vent, or a nitrogen atmosphere. Never store ISO in an open container.

• Use moisture-proof hoses specifically designed for ISO, such as those supplied with your system.

• Never use reclaimed solvents, which may contain moisture. Always keep solvent containers closed when not in use.

• Never use solvent on one side if it has been con-taminated from the other side.

• Always lubricate threaded parts with ISO pump oil or grease when reassembling.

Changing Materials• When changing materials, flush the equipment mul-

tiple times to ensure it is thoroughly clean.

• Always clean the fluid inlet strainers after flushing.

• Check with your material manufacturer for chemical compatibility.

Spraying or dispensing materials containing isocya-nates creates potentially harmful mists, vapors, and atomized particulates.

Read material manufacturer’s warnings and mate-rial MSDS to know specific hazards and precautions related to isocyanates.

Prevent inhalation of isocyanate mists, vapors, and atomized particulates by providing sufficient ventila-tion in the work area. If sufficient ventilation is not available, a supplied-air respirator is required for everyone in the work area.

To prevent contact with isocyanates, appropriate personal protective equipment, including chemically impermeable gloves, boots, aprons, and goggles, is also required for everyone in the work area.

Some materials may become self-igniting if applied too thickly. Read material manufacturer’s warnings and material MSDS.

Cross-contamination can result in cured material in fluid lines which could cause serious injury or dam-age equipment. To prevent cross-contamination of the equipment’s wetted parts, never interchange component A (isocyanate) and component B (resin) parts.

Glossary of Terms

3A1080G 9

Glossary of TermsAdvanced Web Interface (AWI) - This allows remote ProMix backup and restore, configuration, logging, and software update options.

Air Chop - the process of mixing air and solvent together during the flush cycle to help clean the lines and reduce solvent usage.

Air Chop Time- duration of each activation of the air purge valve during a chop sequence. User settable from 0.0-99.9 seconds.

Analog - relating to, or being a device in which data are represented by continuously variable, measurable, physical quantities, such as length, width, voltage, or pressure.

B Purge After Chop - Optional 2-second B solvent valve activation after the Chop sequence. This is used to separate the chop material and the Final Purge mate-rial to prevent unwanted mixing.

Basic Web Interface (BWI) - This allows remote Pro-Mix backup and restore, logging, and software update options.

Bootloader - The utility program that handles initial sys-tem startup re-programming of the main ProMix applica-tion.

Chop Time- refers to the total length of the chop sequence during a purge. User settable from 0-999 sec-onds.

Closed Loop Flow Control - refers to the process when the flow rate is adjusted automatically to maintain a constant flow.

Color/Catalyst Purge - refers to the time required to flush the lines from the color or catalyst change module to the mix manifold during a color or catalyst change.

Color/Catalyst Fill - refers to the time required to fill the lines from the color or catalyst change module to the mix manifold.

Command Holdoff - The amount of time that flow rate learning is not allowed after the set point is changed to allow the flow rate to stabilize.

Coriolis Meter - a non-intrusive flow meter often used in low flow applications or with light viscosity, shear sensi-tive, or acid catalyzed materials. This meter uses vibra-tion to measure flow.

Custom Language - A method to load a translation file into the ProMix to display languages other than those built into the system. Only Unicode characters through codespace 0x00FF are supported.

Digital Input and Output - a description of data which is transmitted as a sequence of discrete symbols, most commonly this means binary data represented using electronic or electromagnetic signals.

Discrete I/O - refers to data that constitutes a separate entity and has direct communication to another control.

Dose Size - the amount of resin (A) and catalyst (B) that is dispensed into an integrator.

Dose Time Alarm - the amount of time that is allowed for a dose to occur before an alarm occurs. More than 30 pulses from the flow meter of the active dose valve are needed while the Gun Trigger is on to prevent the alarm.

Dynamic Dosing - Component A dispenses constantly. Component B dispenses intermittently in the necessary volume to attain the mix ratio.

Ethernet - a method for directly connecting a computer to a network or equipment in the same physical location.

ExtSP - External Set Point selection for PLC input of the flow rate set point while operating in Flow Control Over-ride mode.

Fiber Optic Communication - the use of light to trans-mit communication signals. Blue is the transmitter, and black is the receiver. This must be cross-connected between the EasyKey and the Fluid Panel for communi-cation to work. The Fiber Optic cable has a blue band to indicate the proper connection.

Final Purge Source- source of the media used in the final purge cycle. User settable to air purge valve, sol-vent purge valve, or 3rd purge valve.

Final Purge Time- duration of the final purge cycle. User settable from 0-999 seconds.

Glossary of Terms

10 3A1080G

First Purge Source- source of the media used in the first purge cycle. User settable to air purge valve, sol-vent purge valve, or 3rd purge valve

First Purge Time- duration of the first purge cycle. User settable from 0-999 seconds.

Flow Control Resolution - a settable value that allows the flow control system to maximize its performance. The value is based on maximum desired flow rates.

Flow Rate Analog Signal - the type of communication signal that can be used on the ProControl module.

Flow Rate Tolerance - the settable percent of accept-able variance that the system will allow before a flow rate warning occurs.

Flow Set Point - a predefined flow rate target.

Flush Volume Check - system monitors flush volume. E-11 Alarm occurs if minimum volume is not achieved. Minimum flush volume is user settable (0-999 cc).

Global - indicates that values on the screen apply to all recipes, 1 through 60.

Grand Total - a non-resettable value that shows the total amount of material dispensed through the system.

GT-Off Drive Time - The amount of time to regulate the fluid pressure based on the flow rate set point after the gun trigger is closed.

GT-Off Target Rise - The additional time to regulate the fluid pressure based on the flow rate set point after the gun trigger is closed.

Gun Trigger Holdoff - The amount of time that flow rate learning is not allowed after the gun trigger is opened to allow the flow rate to stabilize.

Gun Trigger Input Signal - used to manage ratio assurance dose times and flow control processes.

Intrinsically Safe (IS) - refers to the ability to locate cer-tain components in a hazardous location.

Idle - if the gun is not triggered for 2 minutes the system enters Idle mode. Trigger the gun to resume operation.

Job Total - a resettable value that shows the amount of material dispensed through the system for one job. A job is complete when a color change or complete system flush occurs.

K-factor - a value that refers to the amount of material that passes through a meter. The assigned value refers to an amount of material per pulse.

Kd - refers to the amount the fluid flow system attempts to not overshoot the target set point.

Ki - refers to the degree fluid flow over shoots its set point.

Kp - refers to the speed in which the fluid flow reaches its set point.

Learn Strength - How much and how quickly to apply the difference in the flow rate set point compared to the measured flow rate when updating the flow control data table.

Manual Mode - when the proportioning or flow control system is controlling the inputs without any input from an outside control.

Minimum Material Fill Volume - system monitors material fill volume. E-21 Alarm occurs if minimum vol-ume is not achieved. Minimum material fill volume is user settable (0-9999 cc).

Mix - when cross-linking of the resin (A) and catalyst (B) occurs.

Mix Fill Push - An option for the Autodump selection to automatically clear the Potlife alarm if the gun is in the Gun Flush Box by running new mixed material through the gun.

Mix Input Signal- refers to system mode status where system begins a dose sequence each time the mix sig-nal is made “High”.

Mixed Material Fill Time - the amount of time that is required to load mixed material from the dose valves to the applicator/gun.

Modbus/TCP - a type of communication protocol used to communicate Digital I/O signals over an ethernet.

Network Station - a means to identify a particular indi-vidual proportioning or flow control system.

One-Point Learning - Flow Control table calibration method using learned points above a specified flow rate to interpolate the table at low flow rates with short gun trigger times.

Glossary of Terms

3A1080G 11

Overdose (A, B, C) Alarm - when either the resin (A), or catalyst (B), or reducer (C) component dispenses too much material and the system cannot compensate for the additional material.

Potlife Time - the amount of time before a material becomes unsprayable.

Potlife Volume - the amount of material that is required to move through the mix manifold, hose and applicator before the potlife timer is reset.

Purge - when all mixed material is flushed from the sys-tem.

Purge Drive - The voltage drive during the Purge sequence, maximum of 3300 mV. The response curve of the V/P regulator is not linear, so it may be necessary to test the response using Manual Override mode.

Purge Time - the amount of time required to flush all mixed material from the system.

Purge Volume Alarm - E-11 Alarm occurs if minimum flush volume is not achieved.

Ratio Tolerance - the settable percent of acceptable variance that the system will allow before a ratio alarm occurs.

Sequential Color Change - the process when a color change is initiated and the system automatically flushes the old color and loads a new color.

Sequential Dosing - Components A and B dispense sequentially in the necessary volumes to attain the mix ratio.

Solvent/3rd Purge Valve Chop Time- duration of each activation of the solvent or 3rd purge valve during a chop sequence. User settable from 0.0-99.9 seconds.

Solvent Fill - the time required to fill the mixed material line with solvent.

Solvent Push - enables the user to save some mixed material by pushing it out to the gun with solvent. Requires an accessory solvent meter.

Standby - refers to the status of the system.

System Idle - This warning occurs if the ProControl is set to Mix, and 2 minutes have elapsed since the sys-tem received a flow meter pulse.

Third Purge Valve - refers to the use of three purge valves used to flush some waterborne materials. The valves are used to flush with water, air and solvent.

V/P - refers to the voltage to pressure device in the flow control module.

Valve Holdoff Maximum - The maximum amount of time that flow rate learning is not allowed after a dose valve cycles. The system may internally use a time less than is based on the stability of the fluid meter pulse stream.

Overview

12 3A1080G

OverviewUsage

The Graco ProControl 1KS is an electronic flow control and color change system, for use with most solvent and waterborne epoxy, polyurethane, and acid-catalyzed paints. It is not for use with “quick-setting” paints (those with a potlife of less than 15 minutes).• Has user selectable ratio assurance and can main-

tain up to +/-1% accuracy, depending on materials and operating conditions.

• Models are available to operate air spray or air-assisted systems with a capacity of up to 3800 cc/min.

• Color change options are available for low pressure (300 psi [2.1 MPa, 21 bar]) air spray and high pres-sure (3000 psi [21 MPa, 210 bar]) systems with up to 30 color change valves and up to 4 catalyst change valves.

NOTE: Optional accessories are available for in field installation to achieve 30 colors.

Component Identification and DefinitionSeeTable 1, and FIG. 2 for the wall mount system components.

Table 1: Component Descriptions

Component Description

EasyKey (EK) Used to set up, display, operate, and monitor the system. The EasyKey accepts 85-250 VAC, 50/60 Hz line power and converts that power to acceptable low voltage and optical signals used by other system components.

Fluid Station Control Box (ST)

Includes air control solenoids. Its control board manages all fluid functions.

Fluid Manifold (FM) Includes wall mounting bracket and mountings for the fluid meter and the following valves:

• Pneumatically Operated Dose Valve for component A• Purge Valves for solvent and air purge

Flow Meters (MA, MS)

Four optional flow meters are available from Graco:

• G3000 is a general purpose gear meter typically used in flow ranges of 75-3800 cc/min. (0.02–1.0 gal/min.), pressures up to 4000 psi (28 MPa, 276 bar), and viscosi-ties of 20–3000 centipoise. The K-factor is approximately 0.119 cc/pulse.

• G3000HR is a high resolution version of the G3000 meter. It is typically used in flow ranges of 38–1900 cc/min. (0.01–0.5 gal/min.), pressures up to 4000 psi (28 MPa, 276 bar). and viscosities of 20–3000 centipoise. The K-factor is approximately 0.061 cc/pulse.

• S3000 is a gear meter used for solvents in flow ranges of 38-1900 cc/min. (0.01–0.50 gal/min.), pressures up to 3000 psi (21 MPa, 210 bar), and viscosities of 20–50 centi-poise. The K-factor is approximately 0.021 cc/pulse.

• Coriolis is a specialty meter capable of a wide range of flow rates and viscosities. This meter is available with 1/8 in. or 3/8 in. diameter fluid passages. For detailed information on the Coriolis meter, see manual 313599.The K-factor is user-settable; at lower flow rates use a lower K-factor.

1/8 in. fluid passages: set K-factor to .020 or .061. 3/8 in. fluid passages: set K-factor to .061 or 0.119.

Overview

3A1080G 13

Color Change Valves (ACV) and Color Change Module (CCM)

An optional component. It is available as a color change valve stack for either low or high pressure with up to 30 color change valves. Each stack includes one additional valve for solvent to clean the fluid line between color changes.

Dual Fiber Optic Cable (FO)

Used to communicate between the EasyKey and Fluid Station Control Box.

Fluid Station Control Box Power Supply Cable (PS)

Used to provide power to the Fluid Station Control Box.

Flow Control Regulator Assembly (FC)

Includes an air operated fluid pressure regulator, fluid pressure sensor, voltage to air pressure transducer and circuit board. The function of this unit is to receive the flow ana-log signal and drive (manage) the desired flow rate.

EasyKey (EK) Used to set up, display, operate, and monitor the system. The EasyKey accepts 85-250 VAC, 50/60 Hz line power and converts that power to acceptable low voltage and optical signals used by other system components.

Fluid Station Control Box (ST)

Includes air control solenoids. Its control board manages all fluid functions.

Table 1: Component Descriptions (Continued)

Component Description

Overview

14 3A1080G

Wall Mount System Components

FIG. 2. ProControl 1KS System, shown with G3000 Meter, Color Change, and Flow Control

TI15961b

FO*

FC (see FIG. 4)

PS*

EK

ACV

CCM

MAFM (see FIG. 3)

* See the ProControl 1KS Repair-Parts manual for optional cable lengths.

Air Control Module

Logic Air

Regulator V/P Air

PurgeAir

Fluid

ST

FC Cable*

Overview

3A1080G 15

Key:MA Component A MeterDVA Component A Dose ValveSPV Solvent Purge ValveSS Solvent Purge Valve Solvent Supply Tube

APV Air Purge ValveAT Air Purge Valve Air Supply TubeFIH Fluid Inlet HoseFOH Fluid Outlet Hose

FIG. 3. Fluid Manifold

TI15977a

MA

SPV

DVA

APV

AT

SS

FIH

FOH

FIG. 4. Flow Control Regulator

TI15976a

RegulatorV/P Air

FC Cable

FCFluid In

Fluid Out

EasyKey Display and Keypad

16 3A1080G


DisplayShows graphical and text information related to setup and spray operations. Back light will turn off after 10 minutes without any key press. Press any key to turn back on.

NOTE: Pressing a key to turn on the display back light will also perform the function of that key. If you are unsure whether that key will impact your current opera-tion, use the setup or navigation keys to turn on the dis-play back light.

KeypadUsed to input numerical data, enter setup screens, scroll through screens, and select setup values.

In addition to the numbered keys on the EasyKey key-pad, which are used to enter values in setup, there are keys to navigate within a screen and between screens, and to save entered values. See Table 2.

FIG. 5. EasyKey Display and Keypad

TI11630A

KeypadLCD Display

Navigation Keys Alarm Reset Key

Table 2: EasyKey Keypad Functions (see FIG. 5)

Key Function

Setup: press to enter or exit Setup mode.

Enter: if cursor is in menu box, press Enter key to view menu. Press Enter to save a value either keyed in from the numerical keypad or selected from a menu.

Up Arrow: move to previous field or menu item, or to previous screen within a group.

Down Arrow: move to next field or menu item, or to next screen within a group.

Left Arrow: move to previous screen group.

Right Arrow: move to next screen group.

Alarm Reset: resets alarms.If the display becomes unresponsive, pressing this key 4 times in succession will re-initialize the display.


3A1080G 17

FIG. 6. EasyKey Connections and AC Power Switch

FIG. 7. Fluid Station Control Box Connections

AC Power Switch

Graco Web Interface

Audible AlarmFiber Optic Strain Relief Port

I/S Power Discrete I/O Cable Connector Ports

Ground Screw

Main Power Access Port

TI12638a

TI12657a

Fiber Optic Strain Relief Port

I/S PowerGround Screw

TI15917a

TI15919a

Booth Control(Manual Systems

only)

Muffler

Color Change Module

Logic Air Inlet

TOP VIEW

BOTTOM VIEW

OPEN

CLOSE

A D

OS

E

B D

OS

E

A P

UR

GE

B P

UR

GE

3RD

PU

RG

E

A D

UM

PB

DU

MP

Meter A

Flow Control

Gun Air

Meter B (not used)


18 3A1080G

AC Power SwitchTurns system AC power on or off.

I/S PowerPower circuit to Fluid Station.

Audible AlarmAlerts the user when an alarm occurs. Available settings for selecting which alarms will cause an audible alarm are explained in Configure Screen 1, page 29.

Clear the audible alarm by pressing the Alarm Reset

key.

Even after the Alarm Reset key is pressed, the Potlife Exceeded alarm message will remain displayed until a sufficient amount of mixed material has been dispensed to ensure that the expired material has been ejected.

Graco Web Interface PortUsed to communicate with the ProControl from a PC to:

Upgrade software View software version Download

• Job and alarm logs• Material usage report• Setup values (can also upload)

Clear job, alarm, and material usage reports Upload a custom language to view on

screen Restore factory defaults Restore setup password

See manual 313386 for more information.

NOTE: If using the Graco Gateway in your system, dis-connect its cable from the EasyKey before updating the ProControl software.

Ethernet ConnectionYou can access data on an office or industrial network through the internet with the proper configuration. See manual 313386 for more information.

Run Mode Screens

3A1080G 19

Run Mode ScreensNOTE: See FIG. 10 for a map of the Run screens. Detailed screen descriptions follow.

Splash ScreenAt power up, the Graco logo and software revision will display for approximately 5 seconds, followed by the

Status Screen (see page 21).

The Splash screen will also momentarily display “Estab-lishing Communication.” If this display remains for more than one minute, check that the fluid station circuit board is powered up (LED is on) and that the fiber optic cable is properly connected (see Installation manual).

NOTE: If the software version of the fluid plate does not match the version of the EasyKey, the EasyKey will update the fluid plate, and the fluid plate programming

screen will appear until the update is completed.

FIG. 8. Splash Screen

FIG. 9. Fluid Plate Programming Screen

Run Mode Screens

20 3A1080G

.

FIG. 10. Run Screens Map

TI12802a

Press the Setup key to enter Setup mode.

Run Mode Screens

3A1080G 21

Status Screen

• Use the Up or Down keys to scroll through the Run screens.

• Press the Setup key to enter the Setup screens

from the Status screen.

• The other keys have no function in this Status screen.

Key to FIG. 11:

Active Recipe: shows the active recipe.

NOTE: At power up the system defaults to Recipe 61, which is not a valid recipe number.

Status Bar: shows current alarm or operation mode (standby, mix, purge, recipe change, or the current alarm).NOTE: If the auto key board is removed from the EasyKey display board, the Status Bar will read “Auto key not found.” This indicates that the auto-matic mode is not operable.

Target Flow Rate and Current Flow Rate: in cc/min.

Animation: when the gun is triggered, the gun appears to spray and the component A or B hose lights up, showing which component dose valve is open.

Current Date and Time

Screen Number and Scroll Arrows: displays the current screen number and the total number of screens in a group. The Up and Down arrows on the right edge of the screen indicate the scroll feature. The total number of screens in some groups may vary depending on system configuration selections.

Current Flow Control Data: fluid output pressure and voltage of analog signal used for driving the fluid regulator V/P.

The fluid target pressure is shown if Flow Control in Configure Screen 5 on page 30 is set to “On: Setup”.

Lock Symbol: indicates that Setup screens are password protected. See page 26.

FIG. 11. Status Screen

1

2

3

4

5

6

8

77

1

2

3

4

5

6

7

8

Run Mode Screens

22 3A1080G

Manual Override Screen

This screen will appear if Manual Override is set to “On” in Advanced Setup Screen 1 (page 35). It shows the active recipe, new/go to recipe, and manual override mode.

If Flow Control is set to “On” in Configure Screen 5 on page 30, this screen will also display Flow Rate Range, Flow Set Point, Flow Control Calibration (Start/Abort), and Global Flow Control Data Copy (Start/Abort).

Manual Override MenuThis field allows you to set the operating mode from the

EasyKey. Press the Enter key to view the menu, then select the desired operating mode (Standby, Mix, Purge, or Recipe Change). See FIG. 13.

Flow Rate RangeThis screen displays the flow rate range selected on Advanced Setup Screen 5 (see page 37).

Flow Set PointThe Flow Set Point is user settable. If Flow Control Override is set to “Off” or “Pressure” in Advanced Setup Screen 1 on page 35, the Flow Set Point will dis-play as cc/min. Enter the desired flow set point within the range.

If Flow Control Override is set to “% Open,” the Flow Set Point will display as % Open. This percentage relates to the flow control V/P ratio which translates to a fluid flow rate. Set the initial percentage at 35% and increase as necessary to reach the desired flow rate.

Flow Control CalibrationThis field allows you to calibrate flow control for each recipe. The system must be in Mix mode and receiving a

Gun Trigger signal. Press the Enter key to view the menu, then select Start or Abort. See FIG. 14.

The flow rate will drop to 0, then incrementally increase until it reaches the maximum flow rate. To view the progress, go to the Status Screen, page 21. The sys-tem will populate the data for the current recipe. To copy this data to all recipes, see Global Flow Control Data Copy, page 23.

FIG. 12. Manual Override Screen

FIG. 13. Manual Override Menu

FIG. 14. Flow Control Calibration

Run Mode Screens

3A1080G 23

Global Flow Control Data CopyThis field allows you to copy flow control data from the

active recipe to all recipes. Press the Enter key to view the menu, then select Start or Abort. See FIG. 15.

Totals Screen

This screen shows the job totals, fill totals, grand totals, and job number. Use the tabs to reset job totals (Job Complete), reset solvent totals (Rst Solvent), or go to Level Control Screen, page 24.

The job totals generally refer to material dispensed while in Mix mode. This is likely atomized and sprayed material with the gun trigger “On”.

The fill totals generally refer to material dispensed while in Mix-fill mode after a color change or a purge opera-tion. This is likely not sprayed or atomized, and is dis-pensed to a purge container.

Solvent Totals and the Rst Solvent tab only appear if “Meter” is selected under Solvent Monitor in Configure Screen 5 on page 30.

NOTE: Grand totals are not resettable.

Reset Total Screen

If job is reset, job number will increment by one for default.

Reset Solvent Screen

The screen will ask if you want to reset solvent total. Select Yes or No.

FIG. 15. Global FC Data Copy

FIG. 16. Totals Screen

FIG. 17. Reset Total Screen

FIG. 18. Reset Solvent Total Screen

Run Mode Screens

24 3A1080G

Alarms Screen

Two screens show the last 10 alarms. Use the Up or

Down keys to scroll between the two screens.

See Table 17 on page 118 for a list of alarm codes.

Level Control Screen

This screen shows the current volume for each fluid. Adjust the current volumes on this screen, or use the tab to go to Usage (Totals Screen, page 23). The Alarm Level values may be adjusted using the advanced web interface.

See FIG. 21. If the tank volume reaches the low-level threshold, the EasyKey screen will display the Tank Level Low alarm and prompt the user to do one of the following:

1. Refill tank volume to clear the alarm.

2. Resume mixing by selecting “Spray 25% of Remain-der.” If this selection is chosen, a second alarm will occur after 25% of the remaining volume is mixed. Refill tank volume to clear the alarm.

FIG. 19. Alarms Screen

FIG. 20. Level Control Screen

FIG. 21. Tank Level Low Screen (Tank A Shown)

Setup Mode

3A1080G 25

Setup Mode

Press the Setup key to enter Setup mode. NOTE: See FIG. 22 for a map of the Setup screens. Detailed screen descriptions follow.

FIG. 22. Setup Screens Map

To access System Configuration Screens, page 28.

TI12784a

Press the Setup key to enter Setup mode.

This screen appears only if a password is activated.

This screen appears momentarily if a password is activated.

Press the Setup key to exit Setup mode and return to the Status

screen.

To access Advanced Setup Screens, page 34 and Recipe Setup Screens, page 40.

Setup Mode

26 3A1080G

Password ScreenIf a password has been activated (see Configure Screen 1, page 29), the Password screen will appear. You must enter the password to access the Set Up Home Screen. Entering the wrong password returns the display to the Status Screen.

NOTE: If you forget the password, you can reset the password (to 0), using the ProControl Web Interface (see manual 313386).

NOTE: If a password is activated, Setup Locked dis-plays momentarily after exiting Setup mode and return-

ing to the Status Screen. A lock symbol appears

on the Status Screen.

Set Up Home Screen

This screen displays when you enter Setup mode. From it you can go to Recipe and Advanced Setup Screens (pages 34-44) or System Configuration Screens

(pages 28-33). Press the Enter key to go to the selected screen set.

The screen also displays software versions and internet addresses of various components. The values shown in FIG. 25 are only examples and may vary on your screen. See Table 3 for further information.

FIG. 23. Password Screen

FIG. 24. Setup Locked Screen

FIG. 25. Set Up Home Screen

Setup Mode

3A1080G 27

Table 3: Component Software Versions

Component

Display (may vary from examples shown) Description

EK (EasyKey) 3.01.001 EasyKey software version.

FP (Fluid Plate) 3.01.001 Fluid Plate software version.

BC (Booth Control) -.- Booth Control not installed, not detected, or not operational.

1.XX Booth Control software version 1.00 or 1.01.

2.XX Booth Control software version 2.XX.

C1/C2 (Color Change Modules 1 and 2)

-.- Color Change Module 1/2 not installed, not detected, or not opera-tional.

1.XX Color Change Module software version 1.00 or 1.01.

2.XX Color Change Module software version 2.XX.

AK (Autokey) No Key No AutoKey installed or detected. System operates in 2K Manual Mode only

2K-Auto 2K AutoKey detected. System can operate in 2K Manual, Semi-auto-matic, or Automatic Mode.

3K-Auto 3K AutoKey detected. System can operate in 3K Manual, Semi-auto-matic, or Automatic Mode.

XP (XPORT) V6.6.0.2 Example of XPORT network module software version. Other versions are acceptable.

MC (Micro Controller) 1042.0198 Example of fluid plate micro controller version. Other versions are acceptable.

Axx By Cz A30 B4 C4 Color Change board valve configuration. This shows the number of valves available for each of the components. This is set by the config-uration switches on the color change boards connected to the system.

Code Description

- Component not available with this machine configura-tion.

x Component not used with this machine configuration.

1 Component available but no change stack.

4-30 Component available with change stack.Number of valves flushed with a solvent valve.

IP (Internet Address) 192.168.178.3 Example of the address EasyKey is set to for basic and advanced web interface reporting.

MAC (MAC address) 00204AAD1810 Example of internet MAC address. Each EasyKey will have a different value in this format.

Setup Mode

28 3A1080G

System Configuration ScreensNOTE: See FIG. 26 for a map of the System Configura-tion Screens. Detailed screen descriptions follow.

NOTE: Each screen displays the current screen number and the total number of screens in the group.

FIG. 26. System Configuration and Option Screens Map

TI12804a

Setup Mode

3A1080G 29

Configure Screen 1

Language

Defines the language of the screen text. Select English (default), Spanish, French, German, Italian, Dutch, Jap-anese (Kanji), Korean, Chinese (Simplified), and Cus-tom.

NOTE: Refer to document 313386 for instructions on using the Custom Language feature to modify the screens to support undefined languages.

Password

The password is only used to enter Setup mode. The default is 0, which means no password is required to enter Setup. If a password is desired, enter a number from 1 to 9999.

NOTE: Be sure to write down the password and keep it in a secure location.

Display Units

Select the desired display units:

• cc/liter (default)• cc/gallon

Buzzer Alarms

As the default, the alarm buzzer is set to “Potlife Only” and will sound only for the Potlife Alarm (E-2).

Set to “All Alarms” to have the buzzer sound for any alarm.

Set to “All Except Potlife” to have the buzzer sound for any alarm except a Potlife Alarm (E2). This option is not recommended unless another active method of handling the Potlife Alarm is implemented.

Screen Timeout

Select the desired screen timeout in minutes (0-99). 5 is the default.

Configure Screen 2

Month

Enter current month.

Day

Enter current day.

Year

Enter current year (four digits).

Time

Enter current time in hours (24 hour clock), minutes, and seconds. Seconds are not adjustable.

Date Format

Select MM-DD-YYYY, DD-MM-YYYY, or YYYY-MM-DD.

FIG. 27. Configure Screen 1


Setup Mode

30 3A1080G

Configure Screen 3

1K/2K/3K

Set this value to indicate the system performance level designation. Selecting a value other than the installed system level will result in restricted functionality.

Run Mode

NOTE: If an Autokey is installed, additional selections of Semi-Automatic and Automatic are available.

Select the Run mode application from the pulldown menu: Automatic, Semi-Automatic (uses a manual spray gun), or Manual.

Dump Valve A

This field only appears if the color change option is detected from the cc board. Select “On” if an optional Dump Valve A is installed and desired to be used.

3rd Flush Valve

Off is default. If optional 3rd flush valve is used, set to On.

Configure Screen 4

Dose Time Alarm

Enter the dose time (1 to 99 seconds). This is the amount of time allowed for a dose to occur before a dose time alarm occurs.

Configure Screen 5

Flow Control

This field only appears if Run Mode is set to “Automatic” in Configure Screen 3, page 30. Select “On”, “Off”, or “On: Setup”.

If set to “On” Advanced Setup Screen 5, page 37 and Advanced Setup Screen 6, page 38 are added.

If set to “On: Setup” Advanced Setup Screen 5, page 37 and Advanced Setup Screen 6, page 38, and Advanced Setup Screen 7, page 38 are added.

FIG. 29. Configure Screen 3FIG. 30. Configure Screen 4


Setup Mode

3A1080G 31

Special Outputs

Select special outputs (0-4, or 3 + GFB on #4). A selec-tion of “0” will disable use of the Special Outputs. If the “3 + GFB on #4” selection is chosen, the other 3 special outputs (1-3) can be used for user-defined functions and the special output #4 settings will duplicate those set-tings established for the Gun Flush Box.

Each output has two different start times and durations defined on the Recipe Setup screen (Flush and Fill Input is set to “Recipe” in Option Screen 1, page 32), or on the Advanced Setup screen (Flush and Fill Input is set to “Global” in Option Screen 1, page 32).

NOTE: At system power up, the Special Outputs may activate for up to 1/4 second.

Solvent Monitor

Select solvent monitor (Off, Flow Switch, or Meter).

Web Browser IP

The default web browser IP address prefix is 192.168.178.__ Assign a unique number for each EasyKey in your system (1-99) and enter it here.

Configure Screen 6

Flow Set Source

This field only appears if Run Mode is set to “Automatic” in Configure Screen 3, page 30 and Flow Control is set to “On” in Configure Screen 5, page 30. Select “Dis-crete” or “Network.”

Proportioning

Select “Discrete” or “Network.”

Gun 1 Trigger

Select “Discrete”, “Network”, or “AFS 1” if Run Mode is set to “Automatic” or “Semi-automatic” in Configure Screen 3, page 30.

Gun 2 Trigger

Displays AFS if Number of Guns is set to “2” in Config-ure Screen 4, page 30.

Control Network ID

Used for the Graco Gateway network system. See Graco Gateway manual 312785 for further information

FIG. 32. Configure Screen 6 (Automatic mode shown)

Setup Mode

32 3A1080G

Option ScreensNOTE: See FIG. 26 on page 28 for a map of the Option Screens. Detailed screen descriptions follow.

NOTE: Each screen displays the current screen number and the total number of screens in the group.

Option Screen 1

Flush Volume Check

This field only appears if Solvent Monitor is set to “Meter” in Configure Screen 5, page 30.

If set to “On”, Minimum Flush Volume will appear in Recipe Setup Screen 2, page 41.

Flush and Fill Input

If set to “Global”, Color/Catalyst Purge and Color/Cata-lyst Fill are added to Advanced Setup Screen 1, page 35. Advanced Setup Screen 2 and 3 are added. See pages 36-39.

If set to “Recipe”, Color/Catalyst Purge and Color/Cata-lyst Fill are added to Recipe Setup Screen 2, page 41. Recipe Setup Screen 3, 4, and 7 are added. See pages 42-44.

K-factor Input

Global mode is useful when the material properties, flush and fill characteristics, or K-factors are the same for all materials used by the system.

If set to “Global,” Advanced Setup Screen 4, page 37 is added.

If set to “Recipe,” Recipe Setup Screen 5, page 43, is added.

Minimum Material Fill Volume

Enter 0-9999 cc.

Verification Screen

Verification

This screen appears if Flush and Fill Input or K-factor Input are changed from “Recipe” to “Global” in Option Screen 1.

FIG. 33. Option Screen 1

FIG. 34. Verification Screen

Setup Mode

3A1080G 33

Option Screen 2

External Color Change

If set to “Off”, Color/Catalyst Purge Time and Color/Cat-alyst Fill Time appear in Advanced Setup Screen 1, page 35 or Recipe Setup Screen 2, page 41 (depend-ing on whether Flush and Fill Inputs are set to “Global” or “Recipe”).

If set to “On”, these fields are removed from the screens.

Auto Dump

If the auto dump feature is being used, set to “On”. Once the auto dump is enabled, the gun flush box is enabled and the potlife alarm is active for 2 minutes, the system will automatically flush out the old material.

This feature is only available in Semi-automatic mode when a Gun Flush Box is installed.

Flow Rate Monitor

This field only appears if Flow Control is set to “Off” in Configure Screen 5, page 30.

If set to “On,” Recipe Setup Screen 6 on page 43 is added, enabling setting of high and low flow limits.

If set to “Off,” flow rate monitoring is disabled and Rec-ipe Setup Screen 6 on page 43 will not appear.

Solvent Push Enable

NOTE: See Solvent Push Feature on page 101 for more information.

To enable the Solvent Push feature, select “Solvent” or “3rd Valve” (available if 3rd Flush Valve in Configure Screen 3, page 30, is set to “On”).

To disable the Solvent Push feature, set to “Off.”

B Purge After Chop

NOTE: This is used to isolate the Chop cycle from the Final Purge cycle with solvent to prevent reaction issues with some types of materials.

Optional 2-second burst (2 s B) operation of the B Purge valve on the integrator after the Chop cycle.

See Color Change Sequences, page 104 for color change charts and timing information.

FIG. 35. Option Screen 2

Setup Mode

34 3A1080G

Advanced Setup Screens

NOTE: See FIG. 36 for a map of the Advanced Setup Screens. Detailed screen descriptions follow.

FIG. 36. Advanced Setup Screens Map

TI12805b

Advanced Setup screens 2, 3, 4, and 10 appear depending on selections made in Option screens 1 and 2. Screens 5 and 6

appear if Flow Control is set to “On” in Configure screen 5. Screens 5, 6, and 7

appear if Flow Control is set to “On: Setup” in Configure screen 5.

Setup Mode

3A1080G 35

NOTE: Each screen displays the current screen number and the total number of screens in the group. The total number of screens in a group and the fields displayed on each screen may vary depending on selections made in the System Configuration Screens and Option Screens. The title at the top of the Advanced Setup screens will display “Global” when Flush and Fill on Option Screen 1, page 32 is set to “Global”.

Advanced Setup Screen 1

Flow Control Override

This field only appears if Flow Control is set to “On” in Configure Screen 5 on page 30. The selections made will affect the display in Manual Override Screen on page 22. Choose the desired selection as defined below:

Manual Override

This field only appears if Run Mode is set to “Automatic” or “Semi-automatic” in Configure Screen 3, page 30. Set to “On: EK” to override all outside control using the Manual Override “Flow Set Point” control to set the flow rate. Set it to “On: EXT” to use the Flow Set Source on Configure Screen 6, page 31 to determine if the flow rate is set from the Discrete or the Network input. If selected, the Manual Override Screen (page 22) will be added, and the Flow Control Override field appears (see above).

Gun 1/Gun2 Potlife Volume

Enter the potlife volume (1 to 1999 cc) for each gun. This is the amount of material required to move through the mix manifold, hose and applicator/gun before the potlife timer is reset.

Use the following information to determine approximate pot life volume (PLV) in cc:

Integrator manifold and mixer volume = 75 ccSpray Gun Volume = 20 cc

(Hose Volume* x Feet of Hose) + 75 + 20 = PLV

Color/Catalyst Purge

NOTE: ProControl 1KS uses Color only.

This field only appears if the system includes a color change module and Flush and Fill Input is set to “Global” in Option Screen 1, page 32. Enter the purge time (0 to 99 seconds). It refers to the amount of time required to flush the lines from the color or catalyst mod-ule to the dose valve or dump valve.

Color/Catalyst Fill


This field only appears if the system includes a color change module and Flush and Fill Input is set to “Global” in Option Screen 1, page 32. Enter the fill time (0 to 99 seconds). It refers to the time required to fill the lines from the color or catalyst module to the dose valve or dump valve.

FIG. 37. Advanced Setup Screen 1

Selection DescriptionOff Normal operation% Open Flow control regulator is opened to a

desired percentage.Pressure Flow control regulator is opened to a

calibrated pressure.ExtSP External Setpoint. The regulator out-

put voltage is set to a percentage of full scale. The range is 0 to 10000 which correlates to 0 to 100.00%. The register used for this is setup.Reg-ManualPercent, at address 40120.

Hose ID (inches) Volume (cc/foot)*3/16 5.431/4 9.6483/8 21.71

Setup Mode

36 3A1080G


This screen appears only if Flush and Fill Input is set to “Global” in Option Screen 1, page 32.

First Purge Source

Select “Air,” “Solvent,” or “3rd Flush Valve” (available only if 3rd Flush Valve is set to “On” in Configure Screen 3 on page 30).

Chop Type

Select “Air/Solvent” or “Air/3rd Flush Valve” (available only if 3rd Flush Valve is set to “On” in Configure Screen 3 on page 30). This refers to the process of mix-ing air and solvent (or air and 3rd flush fluid) together during the flush cycle, to help clean the lines and reduce solvent usage.

Final Purge Source


Air Chop Time

Enter the air chop time (0.0 to 99.9 seconds).

Solvent Chop Time/3rd Flush Valve Chop Time

Enter the solvent or 3rd flush valve chop time (0.0 to 99.9 seconds).


This screen appears only if Flush and Fill Input is set to “Global” in Option Screen 1, page 32.

If Number of Guns is set to “2” in Configure Screen 4, page 30, a Gun 2 column will appear in this screen.

First Purge Time

Enter the first purge time (0 to 999 seconds).

Total Chop Time

Enter the total chop time (0 to 999 seconds).

Final Purge Time

Enter the final purge time (0 to 999 seconds).

Mixed Material Fill Time

Enter the mixed material fill time (0 to 999 seconds). It refers to the amount of time that is required to load mixed material from the dose valves to the applica-tor/gun.

FIG. 38. Advanced Setup Screen 2FIG. 39. Advanced Setup Screen 3

Setup Mode

3A1080G 37


This screen appears only if K-factor Input is set to “Global” in Option Screen 1, page 32.

K-factor A Meter

Enter the k-factor (cc/pulse) for flow meter A. This is the amount of material that passes through the flow meter per pulse (electrical pulse signal).

K-factor Solvent Meter

This field only appears if Solvent Monitor in Configure Screen 5, page 30, is set to “Meter.” Enter the k-factor (cc/pulse) for the solvent flow meter.


This screen appears only if Flow Control is set to either “On” or “On: Setup” in Configure Screen 5, page 30.

Range

Enter the flow rate range (0-300, 0-600, or 0-1200). This determines the flow control PID loop resolution.

Tolerance

Enter the flow rate tolerance (1 to 99%). This is the per-centage of variance that the system will allow before a flow rate warning/alarm occurs.

Alarm Time

Enter the flow rate alarm time (1 to 99 seconds).

Ki

Enter the flow rate Ki (flow control PID loop integral value). Output drive amount based on the accumulation of error between the command and measured pressures scaled to the output transducer.

Kp

Enter the flow rate Kp (flow control PID loop proportional value). Output drive amount based on the instantaneous error between the command and measured pressures scaled to the output transducer.

Kd

Enter the flow rate Kd (flow control PID loop derivative value). Output drive amount based on the change of error between the command and measured pressures scaled to the output transducer.

FIG. 40. Advanced Setup Screen 4FIG. 41. Advanced Setup Screen 5 (Automatic Mode with Flow Control Only)

Setup Mode

38 3A1080G


This screen appears only if Flow Control is set to either “On” or “On: Setup” in Configure Screen 5, page 30.

One-Point threshold

Flow Control runs in Pressure mode for flow setpoints below this value. If the setpoint is at or above this value, a linear calibration is made from (0, 0) to the point.

Learn Strength

This controls how much of the flow error signal is applied when adjusting the Pressure-Flow curve. It will always target the same flow. Because the flow control drives to pressure, the reported flow rate may jump around. However, if the material is consistent and the pressure is constant, then the actual flow is correct.

Pressure zero offset

Zero-pressure calibration adjustment for pressure sen-sor. Used primarily for accurate flow rate calculation in Pressure mode. This is added to the pressure reading, so a negative value zeroes out a positive offset.

Pressure intercept

Pressure-axis intercept of Pressure-Flow curve to match the slope with the actual response.


This screen appears only if Flow Control is set to “On” in Configure Screen 5, page 30.

Command holdoff

Learn blanking time after setpoint command change. Flow learning is turned off during this interval. May be reduced for systems that have less than around x2 from minimum to maximum pressure setpoints. May need to be increased for systems with wide pressure swings.

Gun trigger holdoff

Learn blanking time after gun trigger is opened. Flow learning is turned off during this interval. May be reduced for high-pressure systems. May need to be increased for low-pressure systems.

GT-Off drive time

Time to drive to pressure while the gun trigger is off.

GT-Off target rise

The additional pressure to control to based on flow rate setpoint when the gun is closed. This allows the system to be close to the pressure target when the gun is opened.

Purge drive

Output drive during the Purge sequence. Maximum of 3300 mV.

Valve holdoff maximum

The maximum learn blanking time after dose valve change. This is adjusted based on how much learning was needed per dose changeover up to this maximum value.

FIG. 42. Advanced Setup Screen 6 FIG. 43. Advanced Setup Screen 7

Setup Mode

3A1080G 39


This screen shows the status of digital inputs, digital out-puts, and the Flow Control voltage input. If box is shaded the input is active. If not, input is off. See pages 52-54 for details on the inputs and outputs.


This screen shows the status of digital inputs and digital outputs. If box is shaded the input is active. If not, input is off. See pages 52-54 for details on the inputs and out-puts.


This screen appears only if Flush and Fill Input is set to “Global” in Option Screen 1, page 32 and Special Out-puts is set to 1, 2, 3, 4, or 3 + GFB on #4 in Configure Screen 5, page 30. The I/O board has four programma-ble outputs.

NOTE: If 3 + GFB on #4 is selected, this screen will only display columns for Special 1, 2, and 3. Column Special 4 is not displayed because this output has assumed the same settings as those assigned to the Gun Flush Box #1.

On-Purge

Delay time at the start of the purge cycle before the Spe-cial Output turns on.

Length

Duration for the Special Output to be active during the purge cycle.

On-Fill

Delay time at the start of the fill cycle before the Special Output turns on.

Length

Duration for the Special Output to be active during the fill cycle.




Setup Mode

40 3A1080G

Recipe Setup Screens

NOTE: See FIG. 47 for a map of the Recipe screens. Detailed screen descriptions follow.

FIG. 47: Recipe Screens MapTI12806a

Recipe 0 Screens

Recipe screens 3, 4, 5, 6, and 7 appear depending on selections made in Option

screens 1 and 2

Setup Mode

3A1080G 41

NOTE: Each screen displays the current screen number and the total number of screens in the group. The total number of screens in a group and the fields displayed on each screen may vary depending on selections made in the System Configuration Screens and Option Screens.

Recipe Setup Screen 1

Color Valve

This field only appears if the system includes a color change module. Enter the color valve number (1 to 30).


Minimum Flush VolumeThis field only appears if Flush Volume Check is set to “On” in Option Screen 1 on page 32. Enter the mini-mum flush volume (0 to 9999 cc). Entering 0 disables this function.

Color/Catalyst Purge


This field only appears if the system includes a color change module and Flush and Fill Input is set to “Rec-ipe” in Option Screen 1, page 32. Enter the purge time (0 to 99 seconds). It refers to the amount of time required to flush the lines from the color or catalyst mod-ule to the dose valve or dump valve.

Color/Catalyst Fill


This field only appears if the system includes a color change module and Flush and Fill Input is set to “Rec-ipe” in Option Screen 1, page 32. Enter the fill time (0 to 99 seconds). It refers to the time required to fill the lines from the color or catalyst module to the dose valve or dump valve.

FIG. 48. Recipe Setup Screen 1

FIG. 49. Recipe Setup Screen 2

Setup Mode

42 3A1080G


This screen appears only if Flush and Fill Input is set to “Recipe” in Option Screen 1, page 32.

First Purge Source


Chop Type


Final Purge Source


Air Chop Time





This screen appears only if Flush and Fill Input is set to “Recipe” in Option Screen 1, page 32.

In Automatic mode, only one gun is allowed. In Semi-automatic mode, two guns are allowed. If Number of Guns is set to “2” in Configure Screen 4, page 30, a Gun 2 column will appear in this screen.

First Purge Time


Total Chop Time


Final Purge Time


Mixed Material Fill Time

Enter the mixed material fill time (0 to 999 seconds). It refers to the amount of time that is required to load mixed material from the dose valves to the applica-tor/gun.

FIG. 50. Recipe Setup Screen 3 FIG. 51. Recipe Setup Screen 4

Setup Mode

3A1080G 43


This screen appears only if K-factor Input is set to “Rec-ipe” in Option Screen 1, page 32.

K-factor A Meter

Enter the k-factor (cc/pulse) for flow meter A. This is the amount of material that passes through the flow meter per pulse (electrical pulse signal).

K-factor Solvent Meter

This field only appears if Solvent Monitor is set to “Meter” in Configure Screen 5, page 30. Enter the k-factor (cc/pulse) for the solvent flow meter.


This screen appears only if Flow Rate Monitor is set to “On” in Option Screen 2 on page 33.

Flow Rate Monitor

Select the desired flow rate monitoring (Off, Warning, or Alarm).

Low Flow Limit

Enter the low flow rate limit (1 to 3999 cc/min).

High Flow Limit

Enter the high flow rate limit (1 to 3999 cc/min).

FIG. 52. Recipe Setup Screen 5 FIG. 53. Recipe Setup Screen 6

Setup Mode

44 3A1080G


This screen appears only if Flush and Fill Input is set to “Recipe” in Option Screen 1, page 32 and Special Out-puts is set to 1, 2, 3, or 4 in Configure Screen 5, page 30. The I/O board has four programmable outputs.

On-Purge


Length


On-Fill


Length


FIG. 54. Recipe Screen 7

Setup Mode

3A1080G 45

Recipe 0 ScreensNOTE: See FIG. 47 on page 40 for a map of the Recipe 0 screens. Detailed screen descriptions follow.

Recipe 0 is typically used in multiple color systems to purge out material lines without loading a new color

NOTE: Each screen displays the current screen number and the total number of screens in the group. The total number of screens in a group and the fields displayed on each screen may vary depending on selections made in the System Configuration Screens and Option Screens.

Recipe 0 Screen 1

First Purge Source


Chop Type


Final Purge Source


Air Chop Time




Recipe 0 Screen 2

If Number of Guns is set to “2” in Configure Screen 4, page 30, a Gun 2 column will appear in this screen.

Color/Catalyst Purge Time


This field only appears if the system includes a color change module. It refers to the amount of time required to flush the lines from the color or catalyst module to the dose valve or dump valve. Enter the purge time (0 to 999 seconds).

First Purge Time


Total Chop Time


Final Purge Time


FIG. 55. Recipe 0 Screen 1 FIG. 56. Recipe 0 Screen 2

Setup Mode

46 3A1080G

Recipe 0 Screen 3

This screen only appears if Solvent Monitor is set to “Meter” in Configure Screen 5, page 30 and Flush Vol-ume Check is set to “On” in Option Screen 1, page 32 or 3rd Flush Valve is set to “On” in Configure Screen 3 on page 30.

Minimum Flush VolumeThis field only appears if Flush Volume Check is set to “On” in Option Screen 1 on page 32. Enter the mini-mum flush volume (0 to 9999 cc).

Exiting Fill SourceThis field only appears if 3rd Flush Valve is set to “On” in Configure Screen 3 on page 30. Select “Off,” “Air,” “Solvent,” or “3rd Valve.”

Exiting Fill TimeThis field only appears if Exiting Fill Source is set to “Air,” “Solvent,” or “3rd Valve.” Enter the time in sec-onds.

Recipe 0 Screen 4

This screen appears only if Flush and Fill Input is set to “Recipe” in Option Screen 1, page 32 and Special Out-puts is set to 1, 2, 3, or 4 in Configure Screen 5, page 30. The I/O board has four programmable outputs.

On-Purge


Length


On-Fill


Length


FIG. 57. Recipe 0 Screen 3

FIG. 58. Recipe 0 Screen 4

Setup Mode

3A1080G 47

Calibration Screen

Use this screen to calibrate a meter. Set to “A Meter” or “Solvent Meter” (available if Solvent Monitor in Config-ure Screen 5, page 30, is set to “Meter”).

• Start - start calibration

• Abort - stop calibration

• Purge - purge sampling valves after calibration

See Meter Calibration, page 102, for when and how to calibrate meter.

FIG. 59. Calibration Screen

Setup Mode

48 3A1080G

ProControl Integration Specifics

3A1080G 49


System Setup for Automatic OperationConfiguration of the options for ProControl 1KS Auto-matic operation is done through a few setup screens. Several utility screens are also available for debug and verification.

First, set the ProControl 1KS to Automatic mode:

If Flow Control is used, then turn it on. There are two activation options: “On”, and “On: Setup”. The only dif-ference is that “On: Setup” allows the display of the “Flow Control Tuning” screen.

Several control interface options are available when using Automatic mode.

Flow Set Source

This appears only if Flow Control is turned on. Select “Discrete” or “Network”.

In Discrete mode control is driven through the analog voltage input. In Network mode control is driven through a Modbus register.

Proportioning

Select “Discrete” or “Network”.

In Discrete mode control is driven through the Discrete I/O board. In Network mode control is driven through a Modbus register.

NOTE: It is not possible to read back the active recipe number using the Discrete I/O interface.

Gun 1 Trigger

Select “Discrete”, “Network”, or “AFS 1”.

In Discrete mode the gun trigger control is read by an EasyKey digital input and sent to the Fluid Panel. In Net-work mode it is written to the EasyKey over the Modbus interface. In AFS 1 mode it is applied to the Fluid Panel in the Hazardous location.

NOTE: Discrete I/O is recommended. It is easy to con-nect in the normal location to the PLC. AFS 1 mode is used for special cases where the gun trigger timing is critical.

NOTE: Network gun trigger with Flow Control has a long time delay through the PLC to ProControl communica-tions structure. This will negatively affect Flow Control operation.





50 3A1080G

Control Network ID

Select the Modbus address of the ProControl 1KS. The range is from 1 though 247.

Modbus communications for reading back information is available even when Discrete I/O control is enabled.

Status Verification of Automatic Operation Several screens allow viewing of control interface status information.

Discrete I/O bits as used on the ProControl 1KS are available in Advanced Setup Screen 8 and Advanced Setup Screen 9 If control is through the Network inter-face the status data comes from those registers.

This data is updated live.

Discrete I/O vs Network CommunicationsThe ProControl 1KS Automatic system does not use a Booth Control. Instead, it uses Discrete I/O or Network Communications to drive the system. Each method can be used exclusively, or both at the same time.

In Automatic mode, the following fields can be set to “Discrete” or “Network” (see Configure Screen 6 on page 31):

• Flow Control• Proportioning• Gun 1 Trigger

NOTE: In Semi-automatic mode, only the Proportioning field is available.

NOTE: The Manual Override function enables you to operate the system before the automation (PLC) is available. Manual Override still requires some communi-cation through Discrete I/O or Network Communica-tions. Although Manual Override is not intended to be the main mode of control, it can be used if proper Gun Trigger Input is provided.




3A1080G 51

Discrete I/ODiscrete I/O requires a 24 Vdc power supply which must be supplied on site. The ProControl does not supply power for Discrete I/O.

See Table 4 on page 54, FIG. 73 on page 63, and Table 9 on page 64 for inputs and outputs. Understanding these inputs and outputs is necessary to properly inte-grate the ProControl 1KS to the automation.

Input and output connections are made at the Discrete I/O terminal strips (FIG. 66) and the discrete I/O board (FIG. 67) inside the EasyKey. Also see the System Electrical Schematic on page 131.

Review the Color Change Charts (FIG. 110-FIG. 119). A full understanding of the color change sequence is nec-essary to properly drive the inputs and monitor the out-puts.

See Advanced Setup Screen 9, page 39. This screen shows the actual status of all inputs and outputs. It is important to ensure that each input from local automa-tion (PLC) is received by the EasyKey and to verify that the ProControl 1KS is sending outputs to the automa-tion.

The following paragraphs describe each discrete I/O function in detail.

FIG. 65: EasyKey Control Boards

Display Board Barrier Board

Discrete I/O Board (see FIG. 67) TI12496a

Terminal Strips (see FIG. 66)


52 3A1080G

Digital InputsSee Automation Flow Charts, pages 55-59.

Mix Start: This is a maintained input. When High, the ProControl 1KS will attempt to enter Mix mode. This Mix Start input should not be attempted unless the Mix-_Ready output is recognized. This ensures that there are no alarms and that the Mix Start input is appropriate.

This input stays High at all times when mixing on demand is required. When Low, the intent is to stop mix-ing material and perform a purge or recipe change.

Do not toggle this input to set the unit to Standby mode during short work stoppages. The ProControl 1KS will automatically go into Idle mode after 2 minutes of inac-tivity. When a Gun Trigger input is seen, the ProControl 1KS will automatically leave Idle mode and resume mix-ing material where it left off.

Purge Start: This is a maintained input. When recog-nized by the ProControl 1KS, the Purge Sequence will start, using the Purge Time from the active recipe. This will also include the Solvent Fill Time. Proper monitoring of the Purge/Color Change Output is required to ensure this function has begun. Once this output is removed, the system will immediately go to Standby mode.

Color Change Start: This is a momentary input, 100 msec minimum. When recognized by the ProControl 1KS, the Color Change sequence will begin, starting at the Color/Catalyst Dump.

NOTE: If the new recipe has the same color as the active recipe, then the Color/Catalyst Dump and Color/Catalyst Fill

Documents

3A1080G, ProControl 1KS Auto, Operation Manual, English · Intrinsically safe equipment that is installed improper ly or connected to non-int rinsically safe equipment will create